Hybrid powered welder

ABSTRACT

An electric arc welder that includes a energy storage device and non-battery power source for the formation of an electric arc. The welder also includes battery charging circuit that controls the charging of the energy storage device by the non-battery power source. The non-battery power source can include an engine driven electric generator, power grid or a fuel cell.

The invention relates to the art of electric arc welding and moreparticularly to an electric arc welder powered by a plurality ofdifferent energy sources.

BACKGROUND OF THE INVENTION

Electric arc welders that generate more than 100 amps of welding currenttypically require a fuel-powered engine to drive an electric generatorwhich in turn generates the required current for a welding operation.The size of the engine and electric generator is dictated by the maximumwelding output rating of the welder. For instance, a welder that israted to generate a 300-amp, 33.3 volt arc requires 10 kilowatts ofpower to generate such an arc. The engine in such a welder must have alarge enough horse power to drive an electric generator to generate atleast 10 kilowatts of power so as to supply the maximum welding outputrating of the welder at any given time. The cost associated with largeengines and associated electric generators significantly increases whenlarge welding currents are required. The size of the engine and electricgenerator and the size of the fuel tank required to power the engineresults in a significant increase in the size and the weight of theengine welder, which also results in increased cost and increasedinconvenience in moving and storage of the welder. The energyinefficiencies that are associated with engine welders are alsosignificant, especially in light of increased energy costs. The dutycycle during a normal stick welding operation is typically between20-40% of the time. As a result, 60-80% of the time, the power beinggenerated by the engine driven electric generator is not used, thus iswasted.

In view of the current state of engine driven welders, there is a needfor a lower cost and/or more energy efficient arc welder.

SUMMARY OF THE INVENTION

The present invention is an improvement in electric arc weldertechnology. The invention is particularly directed to electric arcwelders having hybrid energy sources and the advantages associated withthe use of such hybrid energy sources. The hybrid energy source includesone or more battery power sources and one or more non-battery powersources. The battery power source can be any type or combination ofenergy storage device. Typically the battery power source is formed froma single battery or multiple batteries; however, one or more otherenergy storage devices (e.g., capacitor, inductor, fly wheel, etc.) canbe combined with and/or be used as an alternative to one or morebatteries. The battery power source is typically rechargeable. Whenbatteries are included in the battery power source, the same type ofbattery is typically used; however, this is not required. Thenon-battery power source typically includes an electric generator thatis driven by a fuel-powered engine; however, the non-battery powersource can alternatively include, but is not limited to, one or morefuel cells, solar cells, power grid (e.g., an electric outlet, etc),etc. The electric arc welder typically includes one battery power sourceand one non-battery power source; however, multiple battery powersources and/or multiple non-battery power sources can be used. Ifmultiple non-battery power sources are used by the electric arc welder,the multiple non-battery power sources are typically different; however,this is not required. The use of a hybrid energy source in an electricarc welder provides several advantages. These advantages include, butare not limited to, the use of smaller fuel powered engines to drive anelectric generator, increased energy efficiencies, increased versatilityin using the electric arc welder, less noise, less pollution, lessweight, small size, reduced cost, etc.

In accordance with one aspect of the present invention, there isprovided an electric arc welder including a hybrid energy source thatincludes an engine driven electric generator and at least onerechargeable battery. The design of the engine driven electric generatorcan be similar to previous designs used in current engine electric arcwelders. The engine is typically a diesel powered or gasoline poweredengine; however, other types of engines can be used which utilizedifferent types of fuel mixes. The electric generator generates an ACcurrent. Typically, the current generated by the electric generator isrectified to form a DC current; however, this is not required. Thebattery power source that is used by the electric arc welder is used asthe principal energy source for supplying current for the electric arcor can be used in combination with the non-battery power source tojointly supply current for the electric arc. An electric circuit in theelectric arc welder is typically used to direct the current from one ormore power sources to an electrode as needed during a welding procedure.The electric circuit can also include a waveform controller to controlthe waveform of the welding current. In one non-limiting design, thecurrent generated by the engine driven electric generator is rectifiedto form a DC current. This rectified DC current is then added to the DCcurrent provided by the battery power source. These two currents arethen directed into an electric circuit which forms a particular currentwaveform for use in a particular welding operation. In anothernon-limiting design, the DC current from the battery power source ispassed through a circuit to create an AC current. This AC current isthen combined with the AC current from the engine driven electricgenerator. The accumulative AC current is then directed into an electriccircuit to form the desired current waveform for a particular weldingoperation. In still another non-limiting design, the DC current from thebattery power source is directed into an electric circuit which forms aparticular current waveform for use in a particular welding operation.The AC current generated by the electric generator is rectified into aDC current which is used to recharge the battery power source. As can beappreciated, many other current control systems can be used to form thecurrent waveform for a welding operation can be used. The use of thebattery power source in combination with the engine driven electricgenerator enables the electric arc welder to use a smaller engine thanpreviously required. For example, an electric arc welder that isdesigned to generate a 300-amp current at 33.3 volts has a maximumwelding output rating of 10 kW of power. A conventional engine drivenelectric arc welder would need to have an engine and electric generatorthat could constantly produce this level of power. The normal duty cyclefor most manual stick electric arc welding systems is about 20-40%. As aresult, a welding arc is formed and used only about two to four minutesout of every 10 minutes. Although the current demands from the electricarc generator are only required 20-40% of the time, the engine drivingthe electric generator must constantly produce the maximum requiredpower to ensure that the proper amount of current is instantly availableduring the arc welding procedure. The use of the hybrid power system ofthe present invention overcomes this limitation. A battery power sourceis able to store energy and can supply such stored energy on demand. Assuch, a smaller engine/electric generator size can be utilized to onlyreplenish the energy being used when an arc is generated. The use of asmaller sized engine can result in a reduction in the weight and thematerial costs of the electric arc welder. In addition, the size of thearc welder may be reduced due to the reduction size of the engine. Thesmaller engine also produces less noise and consumes less fuel duringoperation. Less exhaust gases may also be generated by the smallerengine. Furthermore, the energy efficiencies are significantly increasedsince over a majority of the energy generated by the engine welder isstores and/or used to generate an electric arc.

In another and/or alternative aspect of the present invention, there isprovided an electric arc welder including a hybrid energy source thatincludes a fuel cell and a rechargeable battery. The design of the fuelcell can be similar to the fuel cell disclosed in U.S. Pat. No.6,653,596, which is incorporated herein by reference. The fuel cell canbe an “indirect” or “reformer” fuel cell or a “direct oxidation” fuelcell. The one or more fuel cells can be a proton exchange membrane fuelcell, a phosphoric acid fuel cells, an alcohol fuel cell (e.g., ethanol,methanol, etc.), an alkaline fuel cell, a solid oxide fuel cell, and/ora regenerative (reversible) fuel cell. As can be appreciated, othertypes of fuel cells can be used. Typically a plurality of fuel cells arestacked together to increase the voltage and/or current generated by thefuel cells; however, this is not required. The plurality of fuel cellscan be connected together in parallel and/or in series. One or more ofthe products of the fuel cell (e.g., carbon dioxide, carbon monoxide,etc.) can be at least partially used as a shielding gas for the arcwelder. The fuel cell can include a dehumidifier, condenser and/orscrubber to remove undesired gases and/or liquids from the product gasprior to using the product gas as a shielding gas. The one or more fuelcells can be connected to a buck circuit or a boost-buck circuit toincrease the voltage generated by the one or more fuel cells. Thecurrent generated by the one or more fuel cells is typically a DCcurrent that can be used to charge the one or more battery powersources. The battery power source that can be used by the electric arcwelder is used as the principal energy source for supplying current forthe electric arc or can be used in combination with the non-batterypower source to jointly supply current for the electric arc. An electriccircuit in the electric arc welder is typically used to direct thecurrent from one or more power sources to the welding electrode asneeded during a welding procedure. The electric circuit can also includea waveform controller to control the waveform of the welding circuit. Inone non-limiting design, the current generated by the fuel cell powersource and battery power source are directed into an electric circuitwhich forms a particular current waveform for use in a particularwelding operation. In another non-limiting design, the DC current fromthe fuel cell power supply and the battery power source is passedthrough a circuit to create an AC current that is directed into acircuit to form the desired current waveform for a particular weldingoperation. In still another non-limiting design, the DC current from thebattery power supply is directed into an electric circuit which forms aparticular current waveform for use in a particular welding operation.The current generated by the fuel cell power supply is used to rechargethe battery power source. As can be appreciated, many other currentcontrol systems used to form the current waveform for a weldingoperation can be used. The battery power source can be used incombination with the fuel cell to eliminate the need for the fuel cellto constantly generate enough current for the peak current demand duringan arc welding process. The use of the battery power source incombination with the fuel cell power source enables the fuel cell powersource to be sized to merely provide a sufficient amount of power over acertain time period to sustain a charge on the battery power source. Forexample, an electric arc welder that is designed to generate a 300-ampcurrent at 33.3 volts would require an energy source to generate 10 kWof power. The normal duty cycle for most manual stick electric arcwelding systems is about 20-40%. As a result, the welding arc only drawsan average of about 2-4 kW of power. As such, the fuel cell power sourceneed only be sized to supply this lower average amount of power. Thebattery power source could be designed individually or in combinationwith the fuel cell power source to supply sufficient current for peakcurrent demand. During the time period an electric arc is not beinggenerated, the current from the fuel cell power source would be used torecharge the battery power source. As such, the fuel cell power sourceis able to take advantage of the no-load period to store energy in thebattery power source, thereby significantly reducing energy losses andwaste, thus making the welder much more energy efficient. As can beappreciated, the use of the fuel cell power source in combination withthe battery power source enables higher transient power capability tothe welder than possible with a single electrical source. The use of thebattery power source in combination with the fuel cell power source alsoenables the use of fuel cells in welders. Although fuel cells have beenproposed for use in welders, the optimum transient characteristics ofthe fuel cells made the fuel cells difficult to use as a power sourcefor a welder. The combination of a battery power source with the fuelcell power source significantly overcomes these problems. The use of afuel cell power source and a battery power source also results in asignificant reduction of operational noise as compared with enginedriven welders.

In still another and/or alternative aspect of the present invention,there is provided an electric arc welder including a hybrid energysource that includes a fuel cell, and engine driven electric generatorand a rechargeable battery. The current generated by the one or morefuel cells and one or more engine driven electric generators can be usedto charge the one or more battery power sources. The battery powersource that is used by the electric arc welder can be used as theprinciple energy source for the electric arc or can be used incombination with the non-battery power sources (i.e., the fuel cell andthe engine driven welder) to generate the electric arc. An electriccircuit in the electric arc welder can be used to direct the currentfrom one or more power sources to the welding electrode as needed duringa welding procedure. The electric circuit can also include a waveformcontroller to control the waveform of the welding circuit. In onenon-limiting design, the current generated by the fuel cell powersource, the engine driven electric generator and the battery powersource are directed into an electric circuit which forms a particularcurrent waveform for use in a particular welding operation. One or moreof the power supplies can have the current rectified and/or formed in aparticular waveform to be used to generate an electric arc and/orfurther modified prior to being used to generate the electric arc. Instill another non-limiting design, the DC current from the battery powersupply is directed into an electric circuit which forms a particularcurrent waveform for use in a particular welding operation. The currentgenerated by the fuel cell power supply and the engine driven welder areused to recharge the battery power source. As can be appreciated, manyother current control systems used to form the current waveform for awelding operation can be used. The battery power source can be used incombination with the fuel cell and engine driven electric generator toeliminate the need for the fuel cell and/or the engine driven electricgenerator to constantly generate enough current for the peak currentdemand during an arc welding process. The use of the battery powersource in combination with the fuel cell power source and the enginedriven electric generator enables the fuel cell power source and theengine driven electric generator to be sized merely to provide asufficient amount of power over a certain time period to maintain thecharge on the battery power source. The battery power source would bedesigned individually or in combination with the fuel cell power sourceand/or engine driven electric generator to supply sufficient current forpeak current demand. During the time period an electric arc is not beinggenerated, the current from the fuel cell power source and engine drivenelectric generator would be used to recharge the battery power source.As such, the fuel cell power source and the engine driven electricgenerator is able to take advantage of the no-load period to storeenergy in the battery power source, thereby significantly reducingenergy losses and waste, thus making the welder much more energyefficient. As can be appreciated, the use of the fuel cell power sourceand the engine driven electric generator in combination with the batterypower source enables higher transient power capability to the welderthan possible with a single electrical source.

In another and/or alternative aspect of the present invention, thehybrid energy source that is used by the electric arc welder is a moreenergy efficient system. Conventional engine driven welders required theengine to drive an electric generator to produce a constant currentsource for welding, irrespective of whether an electric arc is beingused to form a weld bead. The engine and generator had to be sized toprovide sufficient peak power capabilities to provide for theinstantaneous current demands for the electric arc. This power sourceconfiguration resulted in the need for an oversized engine for mostwelding applications. This power source configuration also resulted inincreased size and weight of the welder and increased operation noise.This power source configuration also resulted in reduced energyefficiencies, especially when the engine operated in idle mode. For somewelding operations, the duty cycle is as low as 20%, thereby resultingin the engine operating in idle mode for up to 80% of time. The fuelused by the engine and any current generated by the electric generatorduring the idle mode was not used to form an electric arc, thusresulting in zero efficiency. The hybrid energy source of the presentinvention significantly reduces this energy waste. During a particularwelding operation, the current being supplied to the welding electrodeis at least partially supplied by the battery power source. The weldercan be designed such that up to 100% of the current for welding isdirectly supplied by the battery power source, or the welder can bedesigned such that a portion of the current is supplied by a batterypower source and a portion is supplied by the non-battery power source(e.g., electric generator, fuel cell, etc.). When an electric arc is notbeing generated for a welding process, the current generated by thenon-battery power source is directed into the battery power source so asto recharge the battery power source. The current being generated by thenon-battery power source is thus being used to recharge the batterypower source and/or to supply current to an electric arc during awelding process resulting in significantly less energy being wastedduring the operation of the electric arc welder. As a result, the use ofthe hybrid power source of the present invention results in a majorityof the power being generated by a non-battery source during theoperation of the welder to be used as power to form the electric arcand/or power to recharge the battery power source. Such high energyefficiencies can be achieved even when the duty cycle for a particularwelding operation is as low as 20%. Energy efficiencies for the hybridpower source can approach 100% even when duty cycles for a weldingoperation are less than 50%. In one embodiment of the invention, thehybrid power source includes an engine driven electric generator and arechargeable battery. The battery power source is used to drive achopper type welding control platform. When a weld bead is being formedon a workpiece, the electrical current stored in the battery powersupply is principally used or is used in conjunction with the currentgenerated from the electric generator to provide current for theelectric arc. During the period of time when an electric arc is notbeing generated, the power from the electric generator is used toreplenish the charge in the battery power source. By using the batterypower source as the partial or sole current supplier for the electricarc, a smaller engine and electric generator can be utilized tosufficiently recharge the battery power system. The normal duty cyclefor most manual stick electric welding processes is about 20-40%. As aresult, the engine/electric generator size can be selected so thatenough current is generated by the electric generator during this dutycycle to maintain an adequate charge on the battery power source forthis particular duty cycle range. For example, an electric welder thatis designed to generate 10 kW of power would only require anengine/electric generator size to produce 4 kW of power using the hybridenergy source design of the present invention. The engine/electricgenerator of a conventional electric arc welder would need to be sizedto produce the full 10 kW of power at all times, even though the weldingarc would only be utilized for 20-40% of the time. In the hybrid energysource, the engine/electric generator size would be selected based uponthe maximum duty cycle for a particular welding operation. For stickwelding, the maximum duty cycle of 40% would be multiplied by themaximum kilowatts of power to be generated by the electric arc welder.For an electric arc welder that required the generation of 10 kW ofpower, the engine/electric generator size would be selected to generateat least 4 kW of power. The 4 kW of power represents the maximum energydraw on the battery power source during a welding operation per hour ofwelding. Since the battery power source can deliver the current ondemand, power generation by the engine driven welder needs to only beenough to recharge the battery power source. In one non-limitingexample, the size of the engine and electric generator is selected togenerate a little more power than the calculated power requirement toaccount for energy losses and/or to provide enough current to properlycharge the battery power source. Typically the engine and electricgenerator is sized to produce at least about 105% of the calculatedpower needed, and more typically at least about 110% of the calculatedpower needed, and generally less than about 200% of the calculated powerneeded. For conventional electric arc welder systems, a 25 hp engine isneeded to generate 10 kW of power, whereas only a 9 hp engine is neededto generate 4 kW of power. The advantages of reducing the size of therequired engine/electric generator as discussed above, in combinationwith the increased energy efficiencies due to less wasted energy by theengine driven electric generator and the reduction in the amount of fuelneeded to run a larger engine, amounts to significant cost savings inthe manufacture and operation of the electric arc welder. In anotherand/or alternative one embodiment of the invention, the hybrid powersource includes one or more fuel cells and a rechargeable battery. Thebattery power source is used to drive a chopper type welding controlplatform. When a weld bead is being formed on a workpiece, theelectrical current stored in the battery power supply is primarily usedor is used in conjunction with the current generated by the one or morefuel cells to provide current for the electric arc. During the period oftime when an electric arc is not being generated, the power from the oneor more fuel cells is used to replenish the charge in the battery powersource. By using the battery power source as the partial or sole currentsupplier for the electric arc, a smaller fuel cell configuration can beused in the welder that is designed to sufficiently recharge the batterypower system during the time period that no electric arc is beinggenerated. The battery power source is selected to be able to providesufficient current during the peak current demand by the welder for ashort period of time. During the time period when there is no currentdemand, the battery power source is recharged so that it can once againsupply sufficient current during the peak current demand by the welder.This energy management system for the hybrid energy source enables asmaller non-battery power supply to be used in combination with abattery power supply to adequately provide the power needs for a welder.

In still another and/or alternative aspect of the present invention, thebattery power source of the hybrid energy source of the electric arcwelder is designed to have an adequate amp-hour size requirement toprovide the welding arc requirements for the maximum welding outputrating of the electric arc welder. In this particular configuration, thenon-battery power source is designed to charge the battery power sourcethrough a charging control system to provide the optimum charge rate formaintaining an adequate charge on the battery power system to operatethe electric arc welder during a particular duty cycle. During thegeneration of an electric arc, the peak current demand for the welderoccurs. The battery power system is designed to supply sufficientcurrent during this peak current demand period for a period of time.Generally, the battery power source is sized to supply sufficientcurrent during a peak current demand period for at least about 30seconds, typically at least about 60 seconds, more typically less thanabout 90 minutes, and even more typically about 2-30 minutes. As can beappreciated, the battery power source can be sized to supply sufficientcurrent during a peak current demand period for other time periods. Thecharging control system for the battery power system can be based upon anumber of different platforms such as, but not limited to, a SCR phaseangle control integral to the rectifier, a chopper-based system, etc. Byusing a battery power source having an adequate amp-hour size to providefor the maximum welding output rating of the electric arc welder, theelectric arc welder can be used for short periods of time without havingto operate or use the non-battery power sources. This feature is usefulfor repair or maintenance welding in areas where sufficient electricalpower is not available to power a line operated welding power source andthe operating of an engine powered welder and/or fuel cell power systemis unacceptable due to noise and/or exhaust issues.

In accordance with yet another and/or alternative aspect of the presentinvention, the electric arc welder is rated at least about 100 amperes.The electric arc welder of the present invention is designed to have anamp rating that is higher than portable electric arc welders that arecommonly sold in retail outlets. These portable electric arc welders arelight duty welders and have amp ratings that are significantly less than200 amps. The electric arc welder of the present invention is designedfor heavier duty use than these portable units and is also designed togenerate significantly larger currents for significantly longer periodsof time.

In accordance with still yet another and/or alternative aspect of thepresent invention, there is provided an electric arc welder having apower source that creates an electric arc between an electrode and aworkpiece wherein the power source includes a battery power source, anon-battery power source and an electric circuit. The power source isdesigned to produce a current of at least about 100 amperes, andtypically at least about 200 amperes; however, other current ratings canbe used. In one embodiment of the invention, the electric circuitincludes a battery charging circuit that at least periodically directscurrent from the non-battery power source to the battery power sourceduring the operation of the non-battery power source to at leastpartially charge the battery power source. The battery charging circuitcan be based on a variety of architectures (e.g., SCR based, chopperbased, etc.). In another and/or alternative embodiment of the invention,the electric circuit can be designed to direct current from thenon-battery power source to the battery power source when an electricarc is not being formed between an electrode and a workpiece. In stillanother and/or alternative embodiment of the invention, the electriccircuit can be designed to continuously direct current from thenon-battery power source to the battery power source. In this particulararrangement, the electric circuit can be designed to prevent any of thecurrent generated by the non-battery power supply to be directly routedto the electric arc, thus the electric arc is fully supplied by currentfrom the battery power source. In yet another and/or alternativeembodiment of the invention, the electric circuit can be designed todirect less current from the non-battery power supply to the batterypower source when an electric arc is generated than when no electric arcis being generated. In this arrangement, a portion or all of the currentgenerated by the non-battery power source is directed to the electricarc and a portion or all of the current generated by the non-batterypower source is directed to the battery power source to recharge thebattery power source when no electric arc is being generated. In stillyet another and/or alternative embodiment of the invention, the batterycharging circuit can include an over charge circuit to preventovercharging the battery power source. In a further and/or alternativeembodiment of the invention, the battery charging circuit can include aSCR phase angle control circuit and a rectifier to convert AC current toDC current for charging the battery power source. In still a furtherand/or alternative embodiment of the invention, the battery chargingcircuit can include a chopper circuit to charge the battery powersource. In yet a further and/or alternative embodiment of the invention,the non-battery power source can include an engine driven electricgenerator, a fuel cell and/or a solar cell. As can be appreciated, thenon-battery power source can also or alternatively be a power grid suchas, but not limited to, an electric outlet and/or powerline. In oneparticular design, the non-battery power source is an engine drivenelectric generator. In another particular design, the non-battery powersource is a fuel cell power system. In still yet a further and/oralternative embodiment of the invention, the battery power source has anamp-hour rating to provide sufficient current to meet the maximumwelding output rating of the electric arc welder for at least about oneminute, and typically at least about five minutes, and more typicallyabout five to sixty minutes. In another and/or alternative embodiment ofthe invention, the electric circuit includes a selector that selectscurrent from the battery power source and/or the non-battery powersource to supply current to the electric arc. The selector can include amanual selector and/or an automatic selector. The automatic selector canbe designed to determine which power source(s) is available and toselect the best power supply configuration based on the available powersources. In another and/or alternative embodiment of the invention, theelectric circuit can include an arc inhibitor that prevents theformation of an electric arc between the electrode and the workpiecewhen a sensed power level of the battery power supply is below apreselected value. The arc inhibitor facilitates in preventing damage tothe power battery power source due to fully discharging the powersource, and/or prevents the formation of an arc that cannot bemaintained due to low power levels. In still another and/or alternativeembodiment of the invention, the electric arc welder includes a wirefeeder.

In accordance with a further and/or alternative aspect of the presentinvention, there is provided an electric arc welder having a batterymonitor that monitors the charge on the battery power source andgenerates a signal that is used to control the current directed to thebattery power source from the one or more non-battery power sources. Thebattery monitor is used to prevent overcharge of the battery powersource so as to extend the life of the battery power source. Many typesof rechargeable batteries can be damaged if over charged. The batterymonitor is used to limit or prevent such damage to the battery powersource. The battery monitor can also be used to activate and/or engage anon-battery power source to begin charging and/or increase the chargerate of the battery power source when the battery monitor detects thatthe battery power source has a lower charge. A low battery charge canresult in the weld arc to be prematurely extinguished if the batterypower source becomes fully discharge prior to completing a weldingprocess. The full discharge of the battery power source can also reducethe life of some type of rechargeable batteries. The battery monitor isalso used to prevent or limit such damage to the battery power sourceand/or premature termination of a welding arc. In one embodiment of theinvention, the battery monitor causes or controls theactivation/deactivation the engine of an engine driven generator tocontrol the charge on the battery power source. In one non-limitingdesign, the welder includes an engine control system that receivesinformation from the battery power source concerning the charge level ofthe battery power source, and uses such information to control theoperation of the engine that drives the electric generator. The enginecontrol system can cause the engine to be turned off when a desiredlevel of charge of the battery power source has been achieved. When thelevel of charge on the battery power source fall below a desired chargelevel, the engine control system can be designed to automatically turnon the engine and/or enable an operator to manually start the engine. Inanother and/or alternative embodiment of the invention, the batterymonitor causes or controls the activation/deactivation of one or morefuel cells to control the charge on the battery power source. In stillanother and/or alternative embodiment of the invention, the batterymonitor causes or controls the activation/deactivation a circuit thatregulates the flow of current from a non-battery power source to thebattery power source to control the charge on the battery power source.In still another and/or alternative embodiment of the invention, thebattery monitor can be designed to generate a signal that providesinformation to an operator about the charge level of the battery, and/orother information about the battery power source.

In accordance with a further and/or alternative aspect of the presentinvention, there is provided an electric arc welder having an opencircuit detector that facilitates in determining whether a welding arcis being formed or about to be formed during the welding process. Whenthe open circuit detector determines that a welding arc is not beingformed or is not about to be formed, the open circuit detector controlsor generates a signal that is used to control the operation of one ormore components of the welder in a manner to conserve the charge on thebattery power source. In one embodiment of the invention, the opencircuit detector controls or generates a signal that is used to controlthe operation of the chopper of the welder. When the open circuitdetector determines that a welding arc is not being formed or is notabout to be formed, the open circuit detector turns off the chopper orgenerates a control signal that is used to turn off the chopper. Thedeactivation of the chopper results in a reduction of the power drain onthe battery power source when the welder in not in use. As a result, theopen circuit detector increases the life of the battery power source,facilitates in the recharging of the battery power source and/orimproves the amount of time the battery power source can supply power tothe welder. As can be appreciated, the open circuit detector can be usedto slow or turn off, or generate a signal that is used to slow or turnoff the operation of one or more other components of the welder thatneed not operate when the open circuit detector determines that awelding arc is not being formed or is not about to be formed. In anotherand/or alternative embodiment of the invention, the open circuitdetector can be used to activate, reactivate or maintain activation, orgenerate a signal that is used to activate, reactivate or maintain theoperation of one or more other components of the welder when the opencircuit detector determines that a welding arc is being formed or isabout to be formed. In still another and/or alternative embodiment ofthe invention, the open circuit detector measures or monitors thevoltage level between a workpiece and the welding electrode tofacilitate in determining whether a weld arc is being formed, whether aweld arc is about to be formed, or whether a weld arc is not beingformed and is not about to be formed. In yet another and/or alternativeembodiment of the invention, the open circuit detector receives a signalfrom a switch or trigger on a welding gun to facilitate in determiningwhether a weld arc is being formed, whether a weld arc is about to beformed, or whether a weld arc is not being formed and is not about to beformed. As can be appreciated, other or additional arrangements can beused by the open circuit detector to facilitate in determining whether aweld arc is being formed, whether a weld arc is about to be formed, orwhether a weld arc is not being formed and is not about to be formed.

One object of the present invention is the provision of an electric arcwelder that is powered by a hybrid energy source.

Another and/or alternative object of the present invention is theprovision of an electric arc welder that can utilize a smallerengine/electric generator in conjunction with a battery power supply togenerate a large welding current during a welding operation.

Still another and/or alternative object of the present invention is theprovision of an electric arc welder that is more energy efficient.

Yet another and/or alternative object of the present invention is theprovision of an electric arc welder that uses a battery power sourceindividually or in combination with another power source to form anelectric arc.

Still yet another and/or alternative object of the present invention isthe provision of an electric arc welder that can be used in a multitudeof environments.

A further and/or alternative object of the present invention is theprovision of an electric arc welder which forms a high quality weld beadbetween two metal plates.

Still a further and/or alternative object of the present invention isthe provision of an electric arc welder that includes a fuel cell and abattery to at least partially supply power to generate an arc between anelectrode and the workpiece.

Yet a further and/or alternative object of the present invention is theprovision of an electric arc welder that reduces noise and/or airpollution during operation.

Another and/or alternative object of the present invention is theprovision of an electric arc welder that control the charge rate to thebattery power source at least partially on the amount of charge on thebattery power source.

Another and/or alternative object of the present invention is theprovision of an electric arc welder that includes an open circuitvoltage detector to control the operation of one or more components ofthe welder.

Still another and/or alternative object of the present invention is theprovision of an electric arc welder that includes one or more controlsystems to increase the life of the battery power source.

These and other objects and advantages will become apparent takentogether with the accompanying drawings.

BRIEF DESCRIPTION OF DRAWINGS

Reference may now be made to the drawings, which illustrate variousembodiments that the invention may take in physical form and in certainparts and arrangements of parts wherein;

FIG. 1 is a wiring diagram of an embodiment of the present invention;

FIG. 2 is a block diagram of an embodiment of the present invention;and, FIG. 3 is a block diagram of an embodiment of the presentinvention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

Referring now to FIGS. 1 and 2 wherein the showings are for the purposeof illustrating the preferred embodiments only and not for the purposeof limiting same, there is illustrated an electric arc welder thatincludes a hybrid energy source. The hybrid energy source of the presentinvention can be substituted for most, if not all, power sourcescurrently used in engine welders. Currently, engine welders are poweredby a gasoline powered or a diesel powered engine used to drive anelectric generator that creates a current used to form an electric arcduring a welding procedure. The size of the engine and electricgenerator used in the engine welder is dependant on the maximum powerrating of the engine welder. The engine and electric generator used inprior engine welders must be of sufficient magnitude to supply themaximum power rating of the engine welder at any time, irrespective ofthe type of duty cycle of a particular welding operation. As a result,these past engine welders, which had a high power rating, included largeengines and electric generators to generate the rated power for theengine welder. The hybrid energy source of the present invention isdesigned to provide large power ratings for an electric arc welderwithout having to use large engines and electric generators as presentlyrequired.

The hybrid energy source of the present invention utilizes two differentpower sources to provide the needed power for an electric arc. One powersource is a rechargeable battery power source. The other power source istypically an engine driven electric generator. For purposes ofdescribing this embodiment of the invention, the hybrid energy sourceonly includes two power sources; however, it can be appreciated thatadditional power sources can be used. In addition, an engine drivenelectric generator is used in this particular embodiment; however, itwill be appreciated that other or additional non-battery power sourcescan be used. The hybrid energy source is designed to have an outputrating of at least about 100 amperes to power a medium or heavy dutywelder.

A variety of electrical wiring diagrams can be used for practicing thepresent invention; however, one embodiment is illustrated in FIG. 1. Thenon-battery power source of welder A is an electric generator 100 havinga plurality of output windings 102, 104, 106. The AC current generatedby the electric generator is rectified by a rectifier bridge 110 thatincludes a line frequency switching network which includes three sets ofSCRs 112, 114, 116 that are controlled by gate leads 112 a, 114 a, 116a.

The rectified current is directed to a battery charging regulator 120used to monitor and control the charging of battery 140. The batterycharging regulator receives a signal from the battery current feed backsensor 130 via lines 132, 134 to determine how much current is flowinginto and/or from the battery. The battery current feed back sensor 130is typically designed to monitor the flow of current to and from thebattery. When the battery current feed back sensor senses the flow ofcurrent from the battery, the battery current feed back sensor will senda signal to the battery charging regulator that the battery is currentlysupplying current to form an electric arc between electrode E andworkpiece W. While the battery is supplying current to the electric arc,the battery charging regulator can be designed such that no charging ofthe battery occurs. When the battery is not supplying current to theelectric arc, the battery charging regulator can be designed to directrectified current from the electric generator to the battery to rechargethe battery. As can be appreciated, the current from the electricgenerator can be directed to electrode E when an electric arc is beinggenerated. As can also be appreciated, the current from the electricgenerator can be directed to the battery even when an electric arc isbeing generated. The battery charging regulator can be designed tomonitor or receive information concerning the charge level of thebattery via lines 122, 124 and to regulate current to the battery tomaintain sufficient charge.

As shown in FIG. 1, the current from battery 140 is directed to achopper 150 which is used to generate the desired waveform of thewelding current. The chopper includes a standard capacitor 152, diode154 and switch 156 that is controlled by weld output control 160 vialine 162. A weld output control 160 is used to control the chopper basedon the current information received from current sensor 170 via lines172, 174 and/or a voltage signal via lines 180, 182. A DC filter in theform of a choke 190 is used to smooth out the welding current tofacilitate in obtaining the desired waveform for the welding current.

The operation of one embodiment of the invention is illustrated by theblock diagram of FIG. 2. As illustrated in FIG. 2, engine 200 drives theelectric generator 210 via a drive shaft 202. The electric generatorgenerates an AC current which is rectified by the rectifier chargingregulator 220. As illustrated in FIG. 2, electric generator 210 also cansupply power to an auxiliary power output 260 for AC current. Inaddition, the AC current from generator 210 can be rectified and bepartially directed to an auxiliary DC power output, not shown. The DCcurrent from rectified charger regulator 220 is directed into batterysystem 230 to charge the battery when a feedback signal 232 indicatesthat the battery needs to be and/or is available for charging. The DCcurrent supplied from the battery of battery system 230 is directed intoa chopper module welding output 240 which is used to form the desiredcurrent waveform during an arc welding process. The D.C. current fromthe rectified charge regular 220 can also be directly fed in the choppermodule welding output 240. As such the D.C. current from the rectifiedcharge regular 220 can be used to only charge battery system 230 or beused to both charge battery system 230 and supply current to choppermodule welding output 240.

An engine control system 270 is provided to control the operation ofengine 200. The engine control system receives a signal via line 272from the battery system, which signal is representative of the charge onthe battery system. When the battery system is fully charged, the enginecontrol system slows or turns off engine 200. When the battery system isless than fully charged and/or below a predefined charge level, theengine control system causes the engine to increase in speed and/or beturned on.

Weld control 250 controls the chopper welding output via signal 252based upon output current information received via line 254. FIG. 2 alsoillustrates that weld control 250 can additionally receive voltageinformation from the DC current being directed from battery system 230to chopper module welding output 240. The DC current from the chopperwelding output is directed into a DC filter choke 260 to smooth out theDC current used for forming the welding arc.

An open circuit detector 280 is provided to determine whether an arc isbeing formed or is about to be formed between the electrode andworkpiece during a welding operation. When open circuit detector 280does not detect an arc, the open circuit detector causes the choppermodule 240 to turn off, thereby reducing a drain of power from thebattery system. In one non-limiting design, the voltage level betweenthe workpiece and electrode is monitored to determine the current stateof the arc.

As illustrated in FIG. 2, all the current directed to the weld output issupplied by battery system 230. In order for the battery system 230 tosupply the total current to the weld output 290, the size of the batterysystem is selected to have an adequate amp-hour size which can supplythe maximum power rating of the welder for a sufficient period of time.Typically, the duty cycle for most manual stick welding is about 20-40%.As a result, during a period of about 10 minutes, an electric arc isgenerated for only two to four minutes. The size and amp rating of thebattery system 230 must be sufficient to at least supply a full amountof power to the electric arc during this duty cycle in order to obtain aproper electric arc during an arc welding process. During the time thatan electric arc is not generated, the rectifier charging regulator 220directs DC current into battery system 230 to recharge the depletedbattery system. It is desirable to select a battery which can rapidlyrecharge so that during the intermittent periods of time wherein anelectric arc is not being generated, the battery can be rapidlyrecharged so that it will be able to generate an electric arc during asubsequent duty cycle. Typically, the amp-hour size of the battery isselected so as to provide the arc welding requirements for the maximumwelding output rating of the welder for at least about one minute, andtypically about 5-45 minutes.

As can be appreciated from the design and operation of the hybrid energysource for welder A, the size of engine 200 and electric generator 210need not be sized to provide the maximum welding output rating of thewelder. The size of engine 200 and electric generator 210 only needs tobe sufficiently sized to provide enough current to the battery ofbattery system 230 to adequately recharge the battery after the batteryhas been partially discharged when forming an electric arc. Forinstance, if the maximum welding output rating of a welder is 10 kW ofpower, and the maximum average duty cycle for a welding operation is40%, the engine and electric generator only needs to produce sufficientcurrent to supply 40% of the maximum welding output rating since onlythis much current is being discharged by the battery system during aparticular duty cycle for the welder. As a result, the size of theengine and the size of the electric generator can be significantlydecreased by using the hybrid energy source of the present invention. Inaddition to the cost savings associated with using a smaller engine andelectric generator, the efficiency rating for the use of the currentgenerated by the electric generator is significantly increased sincemost of the current is used to recharge the battery after it has beenpartially discharged during the formation of an electric arc. In thepast, only 20-40% of the current generated by the electric generator wasused in welding operations when the duty cycle was about 20-40%, Inaddition to the increase in energy usage efficiency, the size of themotor needed to provide sufficient power to meet the maximum weldingoutput rating of the welder is decreased since a smaller engine isneeded to power the hybrid energy source. Another benefit of the hybridenergy source is the ability of the welder to generate a welding currentwithout having to operate engine 200 and electric generator 210. Whenbattery system 230 is fully charged, the battery system has an adequateamp-hour size to provide the welding arc requirements during aparticular period of time. As a result, the welder can be used inlocations where the running of an engine powered welder is unacceptabledue to noise and/or engine exhaust issues.

Referring now to FIG. 3, there is illustrated a welder which is poweredby battery system and a non-battery system such as a fuel cell system,an electric generator, an electric power grid and/or the like. When aplurality of fuel cells are used as the non-battery system, the fuelcells are typically stacked together. A buck circuit and/or a boost-buckcircuit may be provided to increase the voltage of the fuel cell system.Any number of fuel cell types can be used. Typically, a proton exchangemembrane fuel cell is used; however, this is not required. When anelectric power grid is used as the non-battery source, the electricpower grid is typically an electric outlet or plug that is suppliedpower by a local or regional power grid system. When a generator is usedas the non-battery source, the electric generator is typically an enginepower generator as described above with respect to FIG. 2; however, thisis not required. As can be appreciated more than one or type ofnon-battery source can be used to supply current to the welder.

The battery power source of the welder is illustrated as the electricaland mechanical energy storage 310. Typically, the electrical andmechanical energy storage system is made up of one or more rechargeablebatteries; however, the electrical and mechanical energy storage systemmay include or alternatively be a capacitor, an inductor, and/or a flywheel. Connected to the electrical and mechanical energy storage 310 isa power conversion circuit 320. Power conversion circuit 320 convertsthe power between an AC current and a DC current. As can be appreciated,if the electrical and mechanical energy storage 310 consists essentiallyof rechargeable batteries, power conversion circuit 320 could beeliminated. The current flowing from the fuel cell electric power gridand/or the electrical and mechanical energy storage is directed into apower conversion circuit 330. Similar to the power conversion circuit320, power conversion circuit 330 converts the current from a DC sourceto an AC source. It can be appreciated that power conversion circuit 320can be eliminated if a DC current is to be directed to inverter choppercircuit 350. As shown in FIG. 3, the welder can include an auxiliaryelectrical output 360 that can be used to provide electrical power tovarious types of devices that are plugged into the welder. Auxiliaryinverter 340 can be used to modify current from a DC current to an ACcurrent and/or modify the voltage level of the line voltage to be a 120and/or 240 line voltage source to be sent to the auxiliary electricaloutput 360.

An control system 380 is provided to control the operation of or thecurrent being provided by the non-battery source 300. The control systemreceives a signal via line 382 from the electrical and mechanical energystorage system, which signal is representative of the charge or energylevel of the electrical and mechanical energy storage system. When theelectrical and mechanical energy storage system is fully charged, thecontrol system slows or turns off the generator or fuel cell and/ordisengages the power grid from the welder. When the electrical andmechanical energy storage system is less than fully charged and/or belowa predefined charge level, the control system causes the fuel cell orgenerator to turn on and/or generate more current, and/or reengages thepower grid with the welder.

The current flowing from power conversion circuit 330 is directed intoinverter chopper circuit 350 which is used to form the current waveformof the electric arc. The current waveform from the inverter chopper 350is directed to welder output 370 for use in forming a weld bead on aworkpiece.

An open circuit detector 390 is provided to determine whether an arc isbeing formed or is about to be formed between the electrode andworkpiece during a welding operation. When open circuit detector 390does not detect an arc, the open circuit detector causes the inverterchopper 350 to turn off, thereby reducing a drain of power from thenon-battery power system. In one non-limiting design, the voltage levelbetween the workpiece and electrode is monitored to determine thecurrent state of the arc.

In one non-limiting configuration of the welding system illustrated inFIG. 3, the electrical and mechanical energy storage 310 is designed soas to provide the peak energy demand of the welder when the electric arcis formed between an electrode and a workpiece to form a weld bead. Afuel cell is sized and designed to generate a sufficient amount of powerover a period of time so as to recharge the electrical and mechanicalenergy storage device 310 during the time that an electric arc is notbeing generated by the welder.

The invention has been described with reference to preferred andalternate embodiments. Modifications and alterations will becomeapparent to those skilled in the art upon reading and understanding thedetailed discussion of the invention provided herein. This invention isintended to include all such modifications and alterations insofar asthey come within the scope of the present invention.

1. An electric arc welder having a power source that creates an electricarc between an electrode and a workpiece, said power source including aenergy storage device, a non-battery power source and an electriccircuit, said electric circuit including a battery charging circuit thatat least periodically directs current from said non-battery power sourceto said energy storage device during the operation of said non-batterypower source, said electric circuit including a welding circuit thatdirects current from said energy storage device, said non-battery powersource, or combination thereof to form said electric arc.
 2. Theelectric arc welder as defined in claim 1, wherein said non-batterypower source includes an engine driven electric generator, a fuel cell,solar cell, power grid or combination thereof.
 3. The electric arcwelder as defined in claim 1, wherein said battery charging circuitdirects current from said non-battery power source to said energystorage device when an electric arc is not being formed between saidelectrode and workpiece.
 4. The electric arc welder as defined in claim2, wherein said battery charging circuit directs current from saidnon-battery power source to said energy storage device when an electricarc is not being formed between said electrode and workpiece.
 5. Theelectric arc welder as defined in claim 1, wherein said energy storagedevice has an amp-hour rating to provide sufficient current to meet themaximum welding output rating of said electric arc welder for at leastabout one minute.
 6. The electric arc welder as defined in claim 2,wherein said energy storage device has an amp-hour rating to providesufficient current to meet the maximum welding output rating of saidelectric arc welder for at least about one minute.
 7. The electric arcwelder as defined in claim 4, wherein said energy storage device has anamp-hour rating to provide sufficient current to meet the maximumwelding output rating of said electric arc welder for at least about oneminute.
 8. The electric arc welder as defined in claim 1, wherein saidbattery charging circuit includes an over charge circuit to preventovercharging said energy storage device.
 9. The electric arc welder asdefined in claim 7, wherein said battery charging circuit includes anover charge circuit to prevent overcharging said energy storage device.10. The electric arc welder as defined in claim 1, wherein said batterycharging circuit includes a SCR phase angle control circuit and arectifier to convert AC current to DC current for charging said energystorage device.
 11. The electric arc welder as defined in claim 2,wherein said battery charging circuit includes a SCR phase angle controlcircuit and a rectifier to convert AC current to DC current for chargingsaid energy storage device.
 12. The electric arc welder as defined inclaim 9, wherein said battery charging circuit includes a SCR phaseangle control circuit and a rectifier to convert AC current to DCcurrent for charging said energy storage device.
 13. The electric arcwelder as defined in claim 1, wherein said welding circuit includes achopper circuit to control the waveform, current level or combinationsthereof of the arc current.
 14. The electric arc welder as defined inclaim 2, wherein said welding circuit includes a chopper circuit tocontrol the waveform, current level or combinations thereof of the arccurrent.
 15. The electric arc welder as defined in claim 9, wherein saidwelding circuit includes a chopper circuit to control the waveform,current level or combinations thereof of the arc current.
 16. Theelectric arc welder as defined in claim 1, wherein said electric circuitincludes a selector that selects current from said energy storagedevice, non-battery power source, or combination thereof to supplycurrent to said electric arc, said selector including a manual selector,an automatic selector, or combination thereof.
 17. The electric arcwelder as defined in claim 2, wherein said electric circuit includes aselector that selects current from said energy storage device,non-battery power source, or combination thereof to supply current tosaid electric arc, said selector including a manual selector, anautomatic selector, or combination thereof.
 18. The electric arc welderas defined in claim 12, wherein said electric circuit includes aselector that selects current from said energy storage device,non-battery power source, or combination thereof to supply current tosaid electric arc, said selector including a manual selector, anautomatic selector, or combination thereof.
 19. The electric arc welderas defined in claim 15, wherein said electric circuit includes aselector that selects current from said energy storage device,non-battery power source, or combination thereof to supply current tosaid electric arc, said selector including a manual selector, anautomatic selector, or combination thereof.
 20. The electric arc welderas defined in claim 1, including a wire feeder.
 21. The electric arcwelder as defined in claim 18, including a wire feeder.
 22. The electricarc welder as defined in claim 19, including a wire feeder.
 23. Theelectric arc welder as defined in claim 1, wherein said power source hasa rating of at least about 100 amperes.
 24. The electric arc welder asdefined in claim 21, wherein said power source has a rating of at leastabout 100 amperes.
 25. The electric arc welder as defined in claim 22,wherein said power source has a rating of at least about 100 amperes.26. The electric arc welder as defined in claim 1, including an arcinhibitor that prevents formation of an electric arc between saidelectrode and said workpiece when a sensed power level of said batterypower supply is below a preselected value.
 27. The electric arc welderas defined in claim 2, including an arc inhibitor that preventsformation of an electric arc between said electrode and said workpiecewhen a sensed power level of said battery power supply is below apreselected value.
 28. The electric arc welder as defined in claim 24,including an arc inhibitor that prevents formation of an electric arcbetween said electrode and said workpiece when a sensed power level ofsaid battery power supply is below a preselected value.
 29. The electricarc welder as defined in claim 25, including an arc inhibitor thatprevents formation of an electric arc between said electrode and saidworkpiece when a sensed power level of said battery power supply isbelow a preselected value.
 30. The electric arc welder as defined inclaim 1, wherein said energy storage device includes a rechargeablebattery, a capacitor, an inductor, a flywheel or combination thereof.31. The electric arc welder as defined in claim 29, wherein said energystorage device includes a rechargeable battery, a capacitor, aninductor, a flywheel or combination thereof.
 32. The electric arc welderas defined in claim 1, including a control system that obtains chargelevel information from said battery source and generates a signal to atleast partially control said non-battery power source.
 33. The electricarc welder as defined in claim 31, including a control system thatobtains charge level information from said battery source and generatesa signal to at least partially control said non-battery power source.34. The electric arc welder as defined in claim 1, including an opencircuit detector that obtains arc status information and generates asignal to at least partially control said welding circuit.
 35. Theelectric arc welder as defined in claim 33, including an open circuitdetector that obtains arc status information and generates a signal toat least partially control said welding circuit.
 36. A method of formingan electric arc between an electrode and a workpiece comprising: a.providing an electric arc welder that includes a power source, saidpower source including a energy storage device and a non-battery powersource; b. at least periodically charging said energy storage devicefrom current generated from said non-battery power source; and, c. atleast partially forming said electric arc from current from said energystorage device, said non-battery power source, or combination thereof toform said electric arc.
 37. The method as defined in claim 36, whereinsaid non-battery power source includes an engine driven electricgenerator, a fuel cell, solar cell, power grid or combination thereof.38. The method as defined in claim 36, including the step of formingsaid electric arc from current from said energy storage device and saidnon-battery power source.
 39. The method as defined in claim 37,including the step of forming said electric arc from current from saidenergy storage device and said non-battery power source.
 40. The methodas defined in claim 36, including the step of at least partiallycharging said energy storage device by said non-battery power sourcewhen said non-battery source is generating a current and an electric arcis not being formed between said electrode and workpiece.
 41. The methodas defined in claim 37, including the step of at least partiallycharging said energy storage device by said non-battery power sourcewhen said non-battery source is generating a current and an electric arcis not being formed between said electrode and workpiece.
 42. The methodas defined in claim 38, including the step of at least partiallycharging said energy storage device by said non-battery power sourcewhen said non-battery source is generating a current and an electric arcis not being formed between said electrode and workpiece.
 43. The methodas defined in claim 39, including the step of at least partiallycharging said energy storage device by said non-battery power sourcewhen said non-battery source is generating a current and an electric arcis not being formed between said electrode and workpiece.
 44. The methodas defined in claim 36, including the step of selecting a power sourceto supply current to said electric arc.
 45. The method as defined inclaim 37, including the step of selecting a power source to supplycurrent to said electric arc.
 46. The method as defined in claim 42,including the step of selecting a power source to supply current to saidelectric arc.
 47. The method as defined in claim 43, including the stepof selecting a power source to supply current to said electric arc. 48.The method as defined in claim 36, including the step of providing anover charge circuit to prevent overcharging said energy storage device.49. The method as defined in claim 37, including the step of providingan over charge circuit to prevent overcharging said energy storagedevice.
 50. The method as defined in claim 47, including the step ofproviding an over charge circuit to prevent overcharging said energystorage device.
 51. The method as defined in claim 36, wherein saidenergy storage device has an amp-hour rating to provide sufficientcurrent to meet the maximum welding output rating of said electric arcwelder for at least about one minute.
 52. The method as defined in claim50, wherein said energy storage device has an amp-hour rating to providesufficient current to meet the maximum welding output rating of saidelectric arc welder for at least about one minute.
 53. The method asdefined in claim 36, including the step of providing a battery chargingcircuit, said battery charging circuit includes a SCR phase anglecontrol circuit and a rectifier to convert AC current to DC current forcharging said energy storage device.
 54. The method as defined in claim37, including the step of providing a battery charging circuit, saidbattery charging circuit includes a SCR phase angle control circuit anda rectifier to convert AC current to DC current for charging said energystorage device.
 55. The method as defined in claim 45, including thestep of providing a battery charging circuit, said battery chargingcircuit includes a SCR phase angle control circuit and a rectifier toconvert AC current to DC current for charging said energy storagedevice.
 56. The method as defined in claim 54, including the step ofproviding a battery charging circuit, said battery charging circuitincludes a SCR phase angle control circuit and a rectifier to convert ACcurrent to DC current for charging said energy storage device.
 57. Themethod as defined in claim 36, including the step of providing a weldingcircuit to control the waveform, current level or combinations thereofof the arc current.
 58. The method as defined in claim 37, including thestep of providing a welding circuit to control the waveform, currentlevel or combinations thereof of the arc current.
 59. The method asdefined in claim 46, including the step of providing a welding circuitto control the waveform, current level or combinations thereof of thearc current.
 60. The method as defined in claim 52, including the stepof providing a welding circuit to control the waveforrn, current levelor combinations thereof of the arc current.
 61. The method as defined inclaim 36, including the step of providing a wire feeder.
 62. The methodas defined in claim 56, including the step of providing a wire feeder.63. The method as defined in claim 60, including the step of providing awire feeder.
 64. The method as defined in claim 36, wherein said powersource has a rating of at least about 100 amperes.
 65. The method asdefined in claim 62, wherein said power source has a rating of at leastabout 100 amperes.
 66. The method as defined in claim 63, wherein saidpower source has a rating of at least about 100 amperes.
 67. The methodas defined in claim 36, including the step of inhibiting the formationof an electric arc between said electrode and said workpiece when asensed power level of said battery power supply is below a preselectedvalue.
 68. The method as defined in claim 65, including the step ofinhibiting the formation of an electric arc between said electrode andsaid workpiece when a sensed power level of said battery power supply isbelow a preselected value.
 69. The method as defined in claim 66,including the step of inhibiting the formation of an electric arcbetween said electrode and said workpiece when a sensed power level ofsaid battery power supply is below a preselected value.
 70. The methodas defined in claim 36, wherein said energy storage device includes arechargeable battery, a capacitor, an inductor, a flywheel orcombination thereof.
 71. The method as defined in claim 69, wherein saidenergy storage device includes a rechargeable battery, a capacitor, aninductor, a flywheel or combination thereof.
 72. The method as definedin claim 36, including the step of at least partially obtaining chargelevel information from said energy source device and at least partiallycontrolling a charge rate of said energy source device.
 73. The methodas defined in claim 71, including the step of at least partiallyobtaining charge level information from said energy source device and atleast partially controlling a charge rate of said energy source device.74. The method as defined in claim 36, including the step of obtainingarc status information and at least partially controlling an operationof at least one component of said welder based on said arc statusinformation.
 75. The method as defined in claim 73, including the stepof obtaining arc status information and at least partially controllingan operation of at least one component of said welder based on said arcstatus information.